Drive Pinion Flange and Drive Pinion Seal: Removal

WARNING: This page is about a different car, the 2004 Ford Pickup, 2004 Ford Excursion, and 2004 Ford Cab & Chassis. However, it is still accessible from the selected car via links, so may be relevant.

NOTE: The rear axle shafts must be removed to prevent drag during drive pinion bearing preload adjustment.

Remove the rear axle shafts. Refer to WHEEL HUBS & BEARINGS - FULL FLOATING AXLE - FORD .
Remove the driveshaft. Refer to DRIVESHAFT .
Install a Nm (inch-pound) torque wrench on the pinion nut, and record the rotational torque required to maintain rotation of the pinion through several revolutions.

Fig 1: Installing (Inch-Pound) Torque Wrench On Pinion Nut
Courtesy of FORD MOTOR CO.

CAUTION: After removal of the pinion nut, discard it. A new nut must be used for installation.

Fig 2: Removing Pinion Nut

Courtesy of FORD MOTOR CO.

Use the Flange Holder to hold the pinion flange while removing the pinion nut.
Mark the pinion flange in relation to the drive pinion stem to ensure proper alignment during installation.

Fig 3: Identifying Mark Pinion Flange In Relation To Drive Pinion
Courtesy of FORD MOTOR CO.
Use the 2-Jaw Puller to remove the pinion flange.

Fig 4: Removing Pinion Flange
Courtesy of FORD MOTOR CO.
Force up on the metal flange of the rear axle drive pinion seal. Install gripping pliers to the seal flange and strike with a hammer until the rear axle drive pinion seal is removed.

Fig 5: Installing Gripping Pliers To Seal Flange And Strike With A Hammer Until Rear Axle Drive Pinion Seal
Courtesy of FORD MOTOR CO.